Method, Device and System for Winding Up a Film Web

ABSTRACT

The invention relates to a method for winding up a film web, which is created in particular on a film production system, on at least one winding reel, wherein quality features of the winding reel ( 100 ) are determined. In order to determine quality features of the winding reel, at least the following steps are carried out: taking out measurements on the winding reel ( 100 ) and providing measurement values for the measurements; and filtering out at least one item of characteristic data from the measurement values.

The invention relates to a method for winding up a film web according to the preamble of claim 1 as well as a corresponding device according to the preamble of claim 6 as well as a system according to claim 8.

After the production of plastic film webs, these are usually wound up on at least one winding reel in order to transport them in a format as compact as possible and to make them available again later for further processing in a simple manner.

For further processing in particular, it is often important that the winding reel meets certain quality requirements. In order to be able to assess whether these quality requirements are met, quality features of the winding reel are determined. More generally speaking, properties of the winding reel can be determined. These properties can then also include quality features.

The object of the present invention is therefore to propose a method, a device and a system for determining quality features or properties of the winding reel. In particular, the object is to detect, evaluate and/or improve the quality of the winding reel.

According to the invention, this object is achieved by all the features of claim 1. Possible embodiments of the invention are specified in the dependent claims.

According to the present invention, it is provided that at least the following steps are carried out for determining quality features of the winding reel:

-   -   taking out measurements on the winding reel and providing         measurement values for the measurements     -   filtering out at least one item of characteristic data from the         measurement values.

Thus, measurements are first carried out on the winding reel. These may be measurements taken only once, for example on the finished reel, multiple times, continuously and/or periodically. The measurements can first be carried out on a tarred winding sleeve, which later carries the film web in order to determine, for example, the concentricity of the winding sleeve or the arrangement of the sleeves on the winding shaft (detection of sleeve misalignment) as a quality feature. In particular, the measurements can be carried out on a winding reel in the process of being created, i.e., on the winding reel during the winding. Measurements can also be made after the winding reel has been completed.

The production of a winding reel generally refers to the production of web shaped materials. By web shaped materials are meant primarily elastic webs, in special cases also plastic film webs. These webs can be wound, for example, in extrusion processes, especially in a cast and blown film extrusion, but also in coating, printing, laminating and metallizing processes. The present invention can also be used in rewinding and slittering processes.

In this context, it may be the case that several winding reels are created simultaneously on one axis during production. The described process can be used with only one winding reel, but also with several, in particular with all winding reels.

Quality features or properties can be understood, for example, as geometric or optical deviations of an ideal winding reel. An ideal winding reel is in particular cylindrically shaped and optically homogeneous. Deviations from this shape that occur during the winding process are usually referred to as winding defects. Winding defects can occur on the shell surface, but also on the end face of the ideal cylinder.

Quality features can also be defined as the optical properties of the winding reel. Gloss, haze and shadowing of a winding reel can be important quality features or properties.

Various measuring methods are available with which the measurements can be carried out. Measuring methods include, for example, contacting measuring methods and non-contacting measuring methods. Contacting measuring methods are, for example, weight measurements or force measurements on a machine component that is in contact with the winding reel. Geometric measurements, which can be carried out with simple measuring means such as measuring tapes, are also conceivable for taking out measurements. Alternatively or additionally, optical, acoustic and/or electrical measuring methods are conceivable as measuring methods. Even measurement methods that use particle beams are conceivable. All of these measurement methods provide measurement values for the measurements performed, which are provided. In particular, both laser triangulation and optical detection using camera systems are suitable measurement methods. In this context, the measurement methods can be point-based, linear or two-dimensional measurements on the shell and/or end face. In particular, measurement with a linear triangulation sensor is suitable for detection. Other optical measurement methods may use, for example, white light or infrared radiation. A sensor can detect, for example, a shadow cast when using an electromagnetic radiation. In particular, it can be provided to use at least two measuring methods that differ in principle in order to be able to conclude further parameters, in particular parameters that are not directly measured, by combining the respective measurement values.

The information and data flow are described in the figure description using the diagram shown in FIG. 1. The data acquired from the winding reel by the sensor is transmitted to a diagnostic unit. The diagnostic unit in turn condenses the sensor data together with process data and can also directly influence the process in a targeted manner and/or prepare data for the operator and/or transfer data to an evaluation unit. The diagnostic unit can thereby specifically influence the process in order to determine possible causes for properties or quality features of the winding reel or the elastic web, in particular if desired quality features or properties are not achieved. In a further configuration stage, data from the diagnostic unit can be transferred to a reconfiguration unit. This unit adjusts process settings so that the desired properties or quality features of the winding reel or elastic web are achieved. Diagnostic unit and/or reconfiguration unit and/or evaluation unit can be realized by an electronic unit, but corresponding parts of a program can be programmed separately and therefore represent said units.

From the provided measurement values of the sensor, at least one item of characteristic data can then be filtered out in the diagnostic unit. This means that information is obtained from measurement values and/or from parts thereof which can be used for a statement with regard to quality features. Quality features or properties are thus derived from the characteristic data according to the invention. The quality features can also relate to the film web as such, because certain measuring methods measure properties of the film, so that their measurement results relate to the film web. Nevertheless, properties of the film web also have an influence on the winding reel. Alternatively, or additionally, the quality features can refer to the way in which the film web is or was wound up. It should be emphasized that the film web which is wound up has been created on a film production system and is wound up without intermediate storage, i.e., inline Such a film production system is in particular a flat film line or a blown film line.

In particular, it is provided to compare the properties of a winding reel with those of an older winding reel in order to detect long-term changes. This purpose may also be served by comparing data measured at different times but on the same winding reel.

In a further embodiment of the invention, it is provided in particular in the diagnostic unit that one or more characteristic data items are assigned to a winding defect. The characteristic data can thereby originate from measurement values of one or more measurements, which are obtained with one or more measuring devices. In particular, several measurements can be combined to obtain characteristic data. In this way, characteristic data can preferably be assigned to a winding defect. A winding defect can be caused by the formation of the winding reel, by the process steps preceding the winding, such as the setting or holding of parameters when guiding the film web, and/or by the properties of the film web itself. Of course, a winding defect, in particular its type, its frequency and/or its intensity, is a quality characteristic in the sense of the present invention.

The process information, for example set values, measurement values, adjustment values, can also be present in the diagnostic unit and, in particular, evaluated and/or processed together with the sensor data. Likewise, operator instructions can be used to condense the information obtained. At the same time, information from the evaluation unit can be given to the operator, so that the operator is enabled to change the process in such a way that the desired defect or the characteristic property of the winding reel is changed. In a further application, it is also possible to provide the quality features of the winding reel(s) obtained here in the form of a (digital) log, so that subsequent processes can use this information.

In order to be able to define quality features, it is preferably provided that these comprise at least partial quality indicators. In particular, these quality features can indicate whether and to what extent a parameter of the winding reel deviates from an ideal value and/or a set point value. An ideal value can be a theoretically predetermined value. A target value can be any predeterminable value or also an average value from previous measurements. In particular, these key figures and target values are generated, controlled and displayed to the operator via the evaluation unit.

In a preferred embodiment of the invention, it is provided that a winding defect is associated with one or more machine components, product parameters and/or process parameters. In this way, the quality features can be influenced with the aim of producing a qualitatively improved winding reel. Once such an assignment has been made, target-oriented changes can be made to the product or process parameters and/or, for example, machine components can be changed if they are defective. The reconfiguration unit in particular is provided for this purpose. For example, the diagnostic unit can detect when edge trimming blades that trim the edges of the film web are worn. The worn blades result in a larger diameter on the winding reel at the edges than on the rest of the shell surface. In this case, the present invention serves to detect the geometric change on the winding reel already during the winding process and to provide the operator with instructions to replace the worn blades. In a further case, for example, longitudinal grooves on the shell surface of the shell reel can be detected and identified. These grooves, often referred to as tin canning, can also be selected and avoided or even completely eliminated via changes to the process parameters by the reconfiguration unit.

Furthermore, properties of the elastic web can also be determined, for example by drawing conclusions about an uneven thickness distribution of the elastic web from detected elevations on the winding reel—so-called thick spots. The reconfiguration unit can then be used to homogenize the thickness distribution by adjusting the process parameters.

The above-mentioned object can also be achieved by a device for winding up a film web, which can be created in particular on a film production system, on at least one winding reel, having a diagnostic unit which is provided and set up for determining quality features of the winding reel,

-   -   which is characterized     -   in that a measuring device is provided, with which measurements         can be carried out on the winding reel and with which         measurement values can be provided for the measurements of the         diagnostic unit,     -   in that the diagnostic unit is provided and set up to filter out         at least one item of characteristic data from the measurement         values, and in that in particular the diagnostic unit is         provided and set up for filtering out quality features from the         characteristic data.

The same advantages are thus achieved as they have already been described in connection with the method according to the invention.

The above-mentioned object can furthermore be achieved by a system for producing and winding up a film web comprising a film production system, with which the film web can be created, a winding device, with which the film web can be wound on at least one winding reel, with a diagnostic unit, which is provided and set up to determine quality features of the winding reel,

-   -   which is characterized     -   in that a measuring device is provided, with which measurements         can be carried out on the winding reel and with which         measurement values can be provided for the measurements of the         diagnostic unit,     -   in that the diagnostic unit is provided and set up to filter out         at least one item of characteristic data from the measurement         values, and in that in particular the diagnostic unit is         provided and set up for filtering out quality features from the         characteristic data.

The same advantages are thus achievable as they have already been described in connection with the method according to the invention.

The features mentioned in the claims and in the description can be essential to the invention individually or in any combination of the features mentioned. Within the scope of the entire disclosure, features and details described in connection with the method according to the invention naturally also apply in connection with the device according to the invention and/or the system according to the invention and vice versa in each case, so that reference is or can always be made mutually to the individual aspects of the invention with respect to the disclosure. The attached figures are described in more detail below. Both the figures and the following description disclose further features of the invention.

FIG. 1 shows an information and data flow according to the device and method of the invention. The data acquired at the winding reel 100 by the sensor 110 (represented by the arrow 105) are transmitted to a diagnostic unit 120 (arrow 115). The diagnostic unit 120 in turn condenses the sensor data together with process data, represented by the arrow 125, and can directly influence the winding process 130 in a targeted manner (arrow 135) and/or prepare data for the operator and/or transfer data to an evaluation unit 140. The diagnostic unit 120 can thereby specifically influence the process 130 to determine possible causes for properties and/or quality features of the winding reel 100 or the elastic web, in particular if desired quality features or properties are not achieved. In a further configuration stage, data from the diagnostic unit 120 can be transferred to a reconfiguration unit 150 (arrow 145). This unit 150 adjusts settings of the winding process 130 (arrow 155) in such a way that the desired properties or quality features of the winding reel and/or the elastic web are achieved. The reconfiguration unit additionally obtains current data of the winding process for this purpose, which is represented by arrow 165. Diagnostic unit 120 and/or reconfiguration unit 150 and/or evaluation unit 140 can be realized by one electronic unit, but corresponding parts of a program can be programmed separately and therefore represent said units.

FIG. 2 shows a winding reel 100, which exhibits an often-observed defect. Shown is a winding sleeve 200 onto which several layers of a web have already been wound. However, the web has irregularities at its edges, causing the diameter of the winding to have thickenings 205 in the area of the end faces than areas where the diameter is larger than the diameter in the central area of the winding. Any defect may indicate irregularities in the winding device, as well as irregularities in the manufacture of the web itself. However, it may be possible to combine data from the web manufacturing device, such as a film extrusion line, with data from the winding device to eliminate sources of error. For example, if the thickness distribution in the transverse direction of the web is known and within a tolerance value, this indicates that one or more process parameters in the winding device are out of order. For example, side cutting knives may be defective or worn, so that the film is damaged at the edges.

FIG. 3 shows another winding reel 100 with another defect that can be observed in reality. In this case, the film web has been altered, in particular damaged, in the central area due to undesirable influences, which is reflected in longitudinal grooves 210 extending in the circumferential direction, the so-called tin canning.

FIG. 4 shows the main parameters of a winding reel 100. The double arrow 300 indicates the width, the double arrow 310 the diameter of the winding reel. In an ideal winding reel, especially one that is finished, the diameter is constant over the entire width of the winding reel, or at least constant within a predetermined tolerance range. Also, the width is constant over the entire diameter of the winding reel 200 or at least constant within a predetermined tolerance frame. The latter manifests itself, among other things, in the fact that the end face 320 and also the end face opposite the end face 320 is flat or at least flat within a predetermined tolerance frame over the entire diameter of the winding reel 200. In an ideal winding reel 100, the shell surface 330 shows no defects whatsoever.

Reference list 100 Winding reel 105 Arrow for displaying acquired data 110 Sensor 120 Diagnostic unit 125 Arrow for displaying process data 130 Winding process 135 Arrow for displaying 140 Valuation unit 145 Arrow for displaying the data transfer 150 Unit 155 Arrow for displaying the adjustment 165 Arrow for displaying additional current data 200 Winding sleeve 205 Thickenings 210 Longitudinal grooves 300 Double arrow for displaying the width 310 Double arrow for displaying the diameter 320 End face 330 Shell surface 

1. A method for winding up a film web, which is created in particular on a film production system, on at least one winding reel, wherein quality features of the winding reel are determined, characterized in that in order to determine quality features of the winding reel, at least the following steps are carried out: taking out measurements on the winding reel and providing measurement values for the measurements filtering out at least one item of characteristic data from the measurement values.
 2. The method according to claim 1, characterized in that the following step is performed: deriving the quality features from the characteristic data.
 3. The method according to any one of the preceding claims, characterized in that one or more characteristic data items are assigned to a winding defect.
 4. The method according to any one of the preceding claims, characterized in that the quality features at least partially comprise quality indices which in particular indicate deviations from an ideal value and/or nominal value.
 5. The method according to any one of the preceding claims, characterized in that a winding defect is associated with one or more machine components, product parameters and/or process parameters.
 6. A device for winding up a film web, which can be created in particular on a film production system, on at least one winding reel, having an evaluation device which is provided and set up for the purpose of determining quality features of the winding reel, characterized in that a measuring device is provided, with which measurements can be carried out on the winding reel and with which measurement values can be provided for the measurements of the evaluation device, in that the evaluation device is provided and set up to filter out at least one item of characteristic data from the measurement values.
 7. The device according to claim 6, characterized in that the evaluation device is provided and set up for filtering out quality features from the characteristic data.
 8. A system for producing and winding up a film web comprising a film production system, with which a film web can be created, a winding device, with which the film web can be wound on at least one winding reel, with an evaluation device, which is provided and set up to determine quality features of the winding reel, characterized in that a measuring device is provided, with which measurements can be carried out on the winding reel and with which measurement values can be provided for the measurements of the evaluation device, in that the evaluation device is provided and set up to filter out at least one item of characteristic data from the measurement values.
 9. The system according to claim 8, characterized in that the evaluation device is provided and set up for filtering out quality features from the characteristic data. 